2.0 TDi T3 panel van build

[mazz]

This PV belongs too Daz who most who know us will know works for us. We have been slowly building this up, it started as a 1.9 AFN, we have now had it overbored with new 81.5mm KS pistons taking it up to just over 2.0l .It is also now wearing a cute little VNT 20 turbo, pump and injectors have gone off now to be modified, but we are aiming to run around 200hp- 320lbs ft tourqe,we could go a lot more but we want to see how the box holds up first, that is obviously in our local friendly gearbox guru Aidan's hands, but here is a few teasers for now
That new piston smell

Mock build up to make sure that VNT 20 fits ok..... It does

Whooooosh

That's it for now

[syncroandy]

What are the turbo and ex mani from? Will you roll your software or buy that in? I'm tempted to build a harness so I can use a later software flashable ECU with my AFN. For educational purposes like.

[mazz]

Turbo is from a V6 TDi, we have already used one on a T4 2.5tdi and we got that up to 242HP on the rolling road, so again this one will be rolling road tuned, manifold s MK2 GTD which we have modified to suit VNT20

[Cableguy]

Omg, tuning an AFN, I'm following this one

[lloydy]

That turbo/manifold almost looks high enough to drain into the block.
Are the cylinder walls thick enough to stand being bored to that size?

[syncroandy]

Maz, is that a three-stud version of the GTD mani then ? Got a four-stud one lying about here I think.
Ray, plenty of folk have tuned the AFN, a popular one seems to be the PD170 turbo BV43 which is bolt-on to the AFN mani, bigger nozzles and a tune.

[lloydy]

A tune is on the horizon for me, next year i reckon. Going to keep the VNT15 though. Heard of a few issues with the VNT17 with boost creep when fitted to a AFN. I'm hoping with the 0.216 injectors, maxing out the boost for the '15 (18psi) i might get a genuine 140bhp and high 200's in torque.

[syncroandy]

I read somewhere the BV43 can overboost a bit with no DPF, but it should be possible to correct that in the tune.

[mazz]

I'll start at the top
Piston walls are more than thick enough for overbore, you could even go bigger to near enough 2.1 if you want.
Turbo manifold is 4 bolt with our own adapter plate
We have been quietly tuning diesel for some years now, and its popular with the watercooled VAG scene , but not so in the T3 scene, time for a change
Any turbo upgrade really needs a rolling road map to be fair, we tend to see that the ECU tourqe limitation system is constantly trying to ramp down power until vehicle is remapped.
This is a T4 we built about 6 weeks back, running VNT 20 with lots of other goodies
http://youtu.be/8VWavedOe8M" onclick="window.open(this.href);return false;
Final figure is WHP not at flywheel, original HP was 102 BHP at flywheel with 150lbs ft tourqe. Running stock map it ran a first run of 192 HP 250lbs ft tourqe, but then we found more .... Which was nice .

[mazz]

Lloydy you should easily pull 140hp with your current set up. And one of our main concerns was getting turbo as high as possible, but still returning into sump

[lloydy]

Lloydy you should easily pull 140hp with your current set up

would be nice if it is, but i will be amazed if it is that high, with a remap, maybe.... Got a rolling road booked for saturday, so we'll see.. The only power mod i have is one size bigger injectors, so i thought maybe 10bhp increase over whatever it was.

[keytouch]

So what kind of price would we be looking at for one of those beasts then?

[mazz]

Lloydy I think you will be pleasantly surprised you have a vehicle with a far better flowing exhaust than a Passat ,plus a charge cooler. Look forward to seeing results.

[Cableguy]

Sounds interesting, wonder how the t3 box would stand up?
My Kennedy flywheel does have some updated clutch options
When Simon drove mine, he said it was the fastest AFN'd van he'd driven.

[mazz]

Sounds interesting, wonder how the t3 box would stand up?
My Kennedy flywheel does have some updated clutch options
When Simon drove mine, he said it was the fastest AFN'd van he'd driven.

What you running in yours,
I don't see any reason a properly built T3 box won't be able to deal with our planned engine mods,
Oh and price for conversion is one unfinished bathroom and a partly finished kitchen refit according to the wife